Hanger beam assembly

ABSTRACT

A main beam support is formed from aluminum and includes an upper end and a lower end. The upper end is attached to a first end of a main beam hanger, while the lower end is attached to a main beam support mounting bracket that is secured to a vehicle floor. The lower end of the main beam support includes first and second sockets with downwardly directed extensions. The first and second sockets are adapted to receive mounting posts that extend from the main beam support mounting bracket. The first socket is disposed relatively vertically above and rearward of the second socket. Integral keys of the main beam support mounting bracket cooperate with the downwardly directed extensions during assembly to align and restrict movement of the main beam support in forward/rearward and up/down directions.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of application Ser. No. 11/469,088, filed Aug. 31, 2006, the disclosure of which is expressly incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed toward an aluminum hanger beam assembly. More particularly, the present invention is directed toward a main beam support that attaches to a main beam hanger and a main beam support mounting bracket.

2. Description of Related Art

Many hanger beam assemblies are known in the art. Such assemblies are structural components that extend between the vehicle A-pillars and serve as a mount for various vehicle components.

A driver beam and a main beam extend between the A-pillars. A variety of brackets/hangers are attached to the driver beam and the main beam. These brackets/hangers are used to mount the vehicle dashboard, instrument panels, control panels, and the steering column assembly. Many types of connection and alignment techniques are utilized to interconnect the brackets/hangers and to connect with the driver and main beams.

These connection and alignment techniques typically include aligning holes between the respective brackets/hangers and driver/main beams and inserting a fastener through the aligned holes. Unfortunately, because the respective holes must be precisely aligned, there is no allowance for tolerances or differences in components of the assembly. Because of this, any dimensional flaws in the assembly cannot be accommodated. If the dimensional flaws in the assembly cannot be accommodated, installation and assembly of the hanger beam assembly in the vehicle is more difficult.

Therefore, there exists a need in the art for a main beam support that absorbs tolerance imperfections in the assembly to facilitate installation and assembly of the hanger beam assembly in the vehicle.

SUMMARY OF THE INVENTION

The present invention is directed toward a main beam support for a vehicle that extends between a main beam support mounting bracket and a main beam hanger. Preferably, the main beam support is formed from aluminum material.

In accordance with the present invention, the main beam support has an upper end that is mechanically secured to the main beam hanger and a lower end that is mechanically secured to the main beam support mounting bracket. The upper end of the main beam support includes a pair of threaded holes for receipt of fasteners for attachment to the main beam hanger. The lower end of the main beam support includes first and second sockets that are adapted to receive corresponding mounting posts that extend from the main beam support mounting bracket.

Downwardly directed extensions of the first and second sockets interact with integral keys of the main beam support mounting bracket so as to align the main beam support with the main beam support mounting bracket. Until a fastener is installed through the main beam support mounting bracket and the main beam support, motion of the main beam support is only restricted in the forward/rearward and up/down directions. However, after the fastener is installed, lateral motion of the main beam support, relative to the main beam support mounting bracket, is also reduced or eliminated.

BRIEF DESCRIPTION OF THE DRAWINGS

These and further features of the invention will be apparent with reference to the following description and drawings, wherein:

FIG. 1A is a perspective view of the hanger beam assembly according to the present invention;

FIG. 1B is a rear elevational view of the hanger beam assembly of FIG. 1A;

FIG. 1C is a top plan view of the hanger beam assembly of FIGS. 1A and 1B;

FIG. 2 is a side view, partially in cross section, of a portion of the hanger beam assembly as seen along line 2-2 of FIG. 1B;

FIG. 3 is a perspective view of a main beam support mounting bracket;

FIG. 4 is a perspective view of a driver beam;

FIG. 5 is a perspective view of a first support bracket;

FIG. 6 is a perspective view of a main beam hanger;

FIG. 7 is an end elevational view primarily illustrating a second support bracket;

FIG. 8 is a perspective view of a steering column support bracket;

FIG. 9 is a perspective view of a main beam support;

FIG. 10 is a rear elevational view of the main beam support of FIG. 9;

FIG. 11 is a side view of the main beam support mounting bracket;

FIG. 12 is a front view of the main beam support mounting bracket; and,

FIG. 13 is an assembly view of the main beam hanger, the main beam support, the main beam support mounting bracket, and a stay.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to the drawings, the present invention is directed toward an improved hanger beam assembly 20 including a driver beam 22, a main beam 24, a first or driver's side support bracket 26, a second or passenger's side support bracket 28, a main beam hanger 30, a main beam support 32, a main beam support mounting bracket 34, a center support 36, dashboard knee bolsters 38, steering column support brackets 40, a stay 42, a lower support beam 44, and a center support bracket 46.

As will be appreciated by those skilled in the art, the hanger beam assembly 20 is a structural assembly to which a vehicle dashboard (not shown) is mounted and on which associated components of the vehicle, such as the steering column assembly, instrument panel, navigation and climate control panels, and glove box, are mounted. As such, the hanger beam assembly 20 extends generally across the entire width of the vehicle, between the driver's side and passenger's side A-pillars (not shown) provided by the vehicle frame.

As will be discussed more fully hereinafter, the components of the hanger beam assembly 20, are preferably formed from aluminum or an aluminum alloy. Components of the hanger beam assembly 20 are welded and/or bolted together to form a unitary, relatively stiff, structure, and cooperate to provide an improved or desirable natural frequency at the steering column assembly 37 (shown in dashed lines in FIG. 1A), which is secured to the hanger beam assembly 20 via the steering column support brackets 40. In the most preferred embodiment, the frequency at the steering column assembly 37 is about 42 Hz.

Generally, and with primary reference to FIGS. 1A-1C, the first support bracket 26 is secured to the vehicle driver's side A-pillar (not shown), and receives a first end 22 a of the driver beam 22. The driver beam 22 extends between the first support bracket 26 and the main beam hanger 30, and has the dashboard knee bolsters 38 and steering column support brackets 40 affixed thereto at predetermined locations. Thus, the second end 22 b of the driver beam 22 is received in the main beam hanger 30, and is supported thereby. The main beam hanger 30 supports both the second end 22 b of the driver beam 22 and a first end 24 a of the main beam 24, and is secured to and extends rearwardly therefrom to an upper end 32 a of the main beam support 32.

The main beam support 32 extends downwardly from the main beam hanger 30, and a lower end 32 b of the main beam support 32 is secured to a first end 34 a of the main beam support mounting bracket 34, which is affixed to a floor frame (not shown) of the vehicle. The main beam 24 extends laterally from the main beam hanger 30 to the second support bracket 28. Thus, a second end 24 b of the main beam 24 is secured to the second support bracket 28, which, in turn, is secured to the vehicle passenger's side A-pillar (not shown). The center support 36 extends between the main beam 24 and a second end 34 b of the main beam support mounting bracket 34. The stay 42 extends laterally between the main beam support 32 and the center support 36. The lower support beam 44 extends between the main beam support 32 and the second support bracket 28 generally parallel to the main beam 24. While the lower support beam 44 is illustrated as being vertically generally even with the stay 42, this is not required.

More specifically, and initially with reference to FIG. 4, the driver beam 22 is preferably extruded from an aluminum alloy material so as to have a generally flat or planar bottom, front, and rear surfaces 22 c, 22 d, 22 e, while a top surface 22 f of the driver beam 22 slopes upwardly from an upper end of the front surface 22 d and then curves rearwardly and downwardly to join with an upper end of the rear surface 22 e. Providing the driver beam 22 with this asymmetrical cross-sectional profile ensures proper angular orientation of the driver beam 22 and positioning of components affixed thereto, while allowing the driver beam 22 to provide a desired strength for resistance to bending.

Notches are formed in the driver beam 22 at the first and second ends 22 a, 22 b whereby the rear surface 22 e, and portions of the bottom surface 22 c and the top surface 22 f are removed to define recessed portions whereby remaining portions of the top, front, and bottom surfaces define extending portions, as illustrated. The thus-modified first and second ends 22 a, 22 b of the driver beam 22 are adapted for receipt in the first support bracket 26 and the main beam hanger 30, respectively. More particularly, the driver beam first and second ends 22 a, 22 b may ‘bottom out’ when fully inserted into the first support bracket 26 and main beam hanger 30, as will be apparent from the drawings and the description to follow. By providing this cooperating structure between the driver beam ends 22 a, 22 b and the first support bracket 26 and the main beam hanger 30, a secure mechanical connection is provide that stiffens the resulting hanger beam assembly 20 without requiring additional mechanical fasteners.

Right and left steering column support brackets 40 and right and left knee bolsters 38 are mounted on the driver beam 22 at predetermined locations between the first and second ends 22 a, 22 b thereof. With reference to FIG. 8, the steering column brackets 40 include a peripheral framework 40 a and first and second internal connecting members 40 b, 40 c. The peripheral framework 40 a includes a planar dash mount 40 d to which an upper dash panel (not shown) is secured. Between the first and second connecting members 40 b, 40 c, an inner surface of the peripheral framework includes a raised ledge 40 e that serves as a stop or positioning means against which the driver beam rear surface 22 e engages.

Thus, the connecting members 40 b, 40 c and framework 40 a cooperate to define an opening 40 f in which the driver beam 22 is received, with the driver beam front surface 22 d abutting a rearwardly facing surface of the first connecting member 40 b and the bottom surface 22 c and rearward portion of the top surface 22 f of the driver beam 22 engaging the inner surfaces of the peripheral framework 40 a. As such, the steering column mounting brackets 40 are initially slidably arranged on the driver beam 22. Once the steering column mounting brackets 40 are placed in the predetermined positions, they are affixed to the driver beam 22 by placing a weld bead between each side of the steering column brackets 40 and the driver beam 22. Welding the steering column support brackets 40 to the driver beam 22 reinforces the driver beam 22 and further stiffens the resulting hanger beam assembly 20.

The knee bolsters 38, which are positioned on each side of the steering column brackets 40, include a mounting end 38 a having an upwardly open U-shaped profile that fits around the front, bottom, and rear surfaces 22 d, 22c, 22 e of the driver beam 22. Once the knee bolsters 38 are in the predetermined position, the mounting end 38 a is welded to the driver beam 22 by placing a weld bead between each lateral side of the mounting ends 38 a and the driver beam bottom, front, and rear surfaces 22 c, 22 d, 22 e.

With reference to FIG. 5, the first support bracket 26 is preferably an extruded and subsequently machined aluminum part. The first support bracket 26 includes a peripheral framework 26 a and upper and lower cross members 26 b, 26 c. The peripheral framework 26 a defines a series of mounting holes 26 d by means of which the first support bracket 26 may be mechanically affixed, via mounting screws, to the driver's side A-pillar. Preferably, the first support bracket 25 is attached at three points to the A-pillar, as illustrated. The cross members 26 b, 26 c cooperate with the peripheral framework 26 a to define a receptacle 26 e into which the driver beam first end 22 a is inserted and received. The peripheral framework includes an inner surface defining a raised ledge 26 f. The ledge 26 f serves as a stop to limit insertion of the driver beam first end into the receptacle 26 e, as noted previously.

Once the first end 22 a of the driver beam 22 is inserted into the receptacle 26 e provided by the first support bracket 26, the first support bracket 26 is welded to the driver beam 22, preferably by laying a weld bead between the first support bracket upper cross member 26 b and the top surface 22 f of the driver beam 22, so as to unify or integrate the first support bracket 26 and the driver beam 22. By interfitting and subsequently welding the driver beam 22 and the first support bracket 26, the stiffness of the resulting connecting is markedly increased as compared to the prior art.

With reference to FIG. 6, the main beam hanger 30 has an open lattice-like structure including a circular portion 30 a, a crosspiece 30 b, a curved top 30 c, and a pair of mounting arms 30 d. The circular portion 30 a defines a main beam receptacle 30 e. The circular portion 30 a, crosspiece 30 b, and curved top 30 c cooperate to define a driver beam receptacle 30 f. The inner surface of the curved top 30 e includes a ledge 30 g that serves as a stop to limit insertion of the driver beam second end 22 b therein.

The driver beam receptacle 30 f is shaped and adapted to receive the second end 22 b of the driver beam 22 from one side thereof facing toward the first support bracket 26. Similarly, the main beam receptacle 30 e is shaped and adapted to receive a first end 24 a of the main beam 24 from the opposite side thereof (i.e., side facing toward the second support bracket 28). The preferred and illustrated main beam 24 is generally tubular in shape, and is preferably an aluminum extrusion.

Once the second end 22 b of the driver beam 22 is inserted into the driver beam receptacle 30 f provided by the main beam hanger 30 (i.e., bottom out), the main beam hanger 30 is welded to the driver beam 22, preferably by laying a weld bead between the hanger curved top 30 c and the top surface 22 f of the driver beam 22, so as to unify or integrate the hanger 30 and the driver beam 22. As with the connection between the driver beam and the first support bracket 26, the interfitting of the driver beam 22 and the hanger 30 serves to greatly increase the resulting stiffness and structural integrity, as compared to the prior art. Similarly, once the first end 24 a of the main beam 24 is inserted into the main beam receptacle 30 e, the main beam 24 is welded to the main beam hanger 30, preferably by a pair of welding beads placed on diametrically opposite positions along the periphery of the main beam 24, so as to positively secure the main beam 24 to the main beam hanger 30 for installation in the host vehicle and subsequent receipt of structural components.

As such, the main beam hanger 30 is positively secured to both the main beam 24 and the driver beam 22 by a plurality of welds. Further, the structural interlocks between the main beam 24, the driver beam 22, and the associated receptacles 26 e, 30 f; 30 c serve to both position and stabilize the main beam hanger 30. Finally, the asymmetrical shape of the driver beam 22 insures that the main beam hanger 30 is properly angularly oriented.

The main beam 24 extends laterally from the main beam hanger 30 to the second support bracket 28. An upper surface 28 a of the second support bracket 28 defines a semi-circular recess 28 b in which the second end 24 b of the main beam 24 rests. Preferably, the main beam second end 24 b is welded to the second support bracket 28 by placing welding beads at positions on a rearwardly laterally outwardly facing surface of the second support bracket 28 and along a upper and lower peripheral surfaces of the main beam second end 24 b.

The main beam hanger mounting arms 30 d extend rearwardly from the main beam hanger 30, and are positioned and adapted to be fixed to the main beam support 32 by a pair of fasteners that extend through threaded openings 30 h formed in the mounting arms 30 d adjacent their distal ends that align with corresponding threaded holes 32 d formed in the main beam support 32.

With reference to FIGS. 9-10, the main beam support 32 is preferably an aluminum casting and has an upper end 32 a and a lower end 32 b. It will be appreciated that the main beam support 32 is a rather complex part that includes a first lateral surface facing toward the first support bracket 26, a second lateral surface facing toward the second support bracket 28, a rear surface facing toward a rear of the vehicle, and a front surface facing toward a front of the vehicle.

The first lateral surface of the main beam support upper end 32 a includes mounting pads 32 c that define the pair of threaded holes 32 d for receipt of the fasteners for securement of the main beam hanger mounting arms 30 d thereto. More specifically, the mounting arms 30 d are brought into face-to-face engagement with the mounting pad 32 c of the main beam support upper end 32 a, and the openings 30 h and holes 32 d are aligned to permit the threaded fasteners to be installed to mechanically affix the main beam hanger 30 to the main beam support 32.

The lower end 32 b of the main beam support 32 includes first and second sockets 32 e, 32 f that are adapted to receive corresponding mounting posts 34 d, 34 e extending from the main beam support mounting bracket 34. The first and second sockets 32 e, 32 f are formed in the second lateral surface of the main beam support 32 such that the sockets 32 e, 32 f are open toward the second support bracket 28. Preferably, the sockets 32 e, 32 f are somewhat elongated vertically, and have downwardly directed extensions 32 i, 32 j, as illustrated. Further, each of the sockets 32 e, 32 f has a bottom surface (i.e., laterally facing toward the first support bracket 26) that is closed with the exception of a slotted opening 32 g that is provided to permit a threaded fastener to extend therethrough. Thus, each socket 32 e, 32 f may be considered to be a laterally open blind bore that is adapted to receive the associated mounting post 34 d, 34 e. The first socket 32 e is disposed relatively vertically above and rearward of the second socket 32 f. The second socket 32 f is generally disposed adjacent a lowermost end of the main beam support 32.

Intermediate the upper and lower ends 32 a, 32 b, the main beam support 32 includes a pair of mounts 32 h that have threaded openings formed therein. The mounts 32 h receive a first end 42 a of the stay 42, and the threaded openings receive fasteners to mechanically affix the stay 42 to the main beam support 32.

With reference to FIG. 3, the main beam support mounting bracket 34 is preferably an aluminum casting that has a generally rectangular footprint and includes a relatively raised first lateral end 34 a facing toward the first mounting bracket 26, and a relatively shorter second lateral end 34 b facing toward the second mounting bracket 28. The raised lateral end 34 a has an end wall 34 c from which the first and second mounting posts 34 d, 34 e laterally extend. The end wall 34 c tapers as it extends vertically so as to provide a structurally stable attachment or mounting structure between the main beam support 32 and the floor frame. The first mounting post 34 d is at a position that is relatively raised as compared to the second mounting post 34 e. Thus, the first mounting post 34 d is positioned to be received in the first socket 32 e, whereas the second mounting post 34 e is disposed at a position to be received in the second socket 32 f. Each of the first and second mounting posts 34 d, 34 e is generally cylindrical has a threaded bore formed centrally or axially therein through which a fastener, such as a bolt, is received to mechanically affix the main beam support lower end 32 b to the main beam support mounting bracket 34.

Preferably, the fasteners are inserted through the slotted openings 32 g in a back wall 32 m of the sockets 32 e, 32 f and threaded into the mounting posts 34 d, 34 e so as to mechanically affix or clamp the main beam support 32 to the main beam support mounting bracket 34. It will be appreciated that receipt of the mounting posts 34 d, 34 e in the sockets 32 e, 32 f reduces or limits possible motion of the main beam support 32 in the forward/rearward and up/down directions, while the fasteners reduce or eliminate possible lateral motion of the main beam support 32 relative to the main beam support mounting bracket 34.

A base or central section of the main beam support mounting bracket 34 provides a series of slotted mounting openings 34 f through which threaded fasteners such as bolts extend for threaded engagement or receipt by corresponding threaded openings (not shown) in the floor or frame of the vehicle. Preferably, two of slotted mounting openings 34 f are provided adjacent the first end 34 a of the main beam support mounting bracket 34 and two of the slotted mounting openings 34 f are provided adjacent the second end 34 b of the main beam support mounting bracket 34.

Thus, the main beam support 32 is mechanically affixed to the main beam support mounting bracket 34, and the main beam support mounting bracket 34 is mechanically affixed to the vehicle floor frame. Further, the main beam support mounting bracket posts 34 d, 34 e are received in the main beam support sockets 32 e, 32 f at a position vertically and horizontally offset from one another. The multi-point mechanical attachment and multi-plane engagement between the main beam support 32 and main beam support mounting bracket 34 results in a structurally stiff and secure integration of the main beam support 32 and main beam support mounting bracket 34.

The second end 34 b of the main beam support mounting bracket 34 includes first and second semi-cylindrical mounting pads 34 g, 34 h over which a lower end 36 b of the center support 36 is placed, as will be apparent from the following description. The first and second mounting pads 34 g, 34 h extend vertically upwardly and have a small locating stub 34 i at their upper end, and a laterally facing surface in which a threaded bore 34 j is formed for receipt of a mounting fastener to secure the center support 36 thereto.

The center support bracket 46 has a first end 46 a secured to the main beam 24 and a second end 46 b to which an upper end 36 a of the center support 36 is secured. The center support bracket first end 46 a is semi-circular and extends partway around the main beam 24, and the center support bracket 46 extends rearwardly therefrom. Preferably, the center support bracket 46 is secured to the main beam 24 by upper and lower weld beads disposed between the free upper and lower terminal surfaces of the center support bracket 46 and the main beam 24.

The center support 36 is generally shaped as an inverted L such that while the upper end 36 a of the center support 36 is affixed to the second end 46 b of the center support bracket 46 and extends rearwardly therefrom, a main portion of the center support 36 extends vertically downward to the lower end 36 b of the center support 36. Intermediate the upper and lower ends 36 a, 36 b, the center support 36 is secured to the second end 42 b of the stay 42, which serves to stabilize and maintain spacing between the main beam support 32 and the center support 36. Also, a first end 44 a of the lower support beam 44 is secured to the center support 36 at a location intermediate the upper and lower ends 36 a, 36 b thereof, and extends first forwardly and then laterally toward the second support bracket 28, as illustrated. The second end 44b of the lower support beam 44 is bolted to the second support bracket 28.

The lower end 36 b of the center support 36 includes first and second downwardly open semi-cylindrical recesses (not shown). The recesses are also open in a lateral direction facing toward the first support bracket 26, such that the recesses define blind bores. Further, the recesses include a vertical extension (not shown) for receipt of the mounting stubs 34 i extending upwardly from the mounting pads 34 g, 34 h. A pair of threaded openings extends laterally through the lower end of the center support 36 and are aligned with the threaded bores 34 j in the laterally facing surfaces of the mounting pads 34 g, 34 h.

Thus, when the center support 36 is positioned on the main beam support mounting bracket 34, the mounting stubs 34 i extend into the recess extensions, the mounting pads 34 g, 34 h are received in the recesses, and then the bolts 48 (FIG. 1A) are threaded into the aligned openings and bores in the center support 36 and mounting pads 34 g, 34 h to mechanically affix the center support 36 to the main beam support mounting bracket 34.

While it is considered apparent that the hanger beam assembly 20 may be assembled in many different ways, the following is provided to generally describe one preferred method or sequence of assembly. During assembly, preferably the knee bolsters 38 and steering column support brackets 40 are first disposed at their predetermined positions along the length of the driver beam 22, and then welded thereto. Thereafter, the main beam hanger 30 is placed on the main beam 24, and welded thereto, and the first and second ends 22 a, 22 b of the driver beam 22 are pushed into the receptacles 26 e, 30 f in the first support bracket 26 and main beam hanger 30, respectively, and then welded thereto. This defines a first subassembly of the hanger beam assembly 20. Then, the second end 24 b of the main beam 24 placed on the semi-circular recess 28 b of the second support bracket and welded the second support bracket 28, and the center support bracket 46 is positioned on the main beam 24 and welded thereto. This defines a second subassembly for the hanger beam assembly 20.

Thereafter, the first and second subassemblies are assembled by pushing the first end 24 a of the main beam 24 into the receptacle 30 e of the main beam hanger 30, and welding the main beam first end 24 a to the main beam hanger 30. The so-assembled first and second subassemblies define a beam component.

The stay second end 42 b and lower support beam first end 44 a are welded to the center support 36 to define a center support assembly. Thereafter, the center support assembly is secured to the main beam support mounting bracket 34 by bolting the lower end of the center support to the mounting bracket 34. Then, the main beam support 32 is bolted to the main beam hanger 30 and the main beam support mounting bracket 34 to substantially complete the hanger beam assembly 20. Thereafter, the assembled hanger beam assembly 20 may be installed in a vehicle by bolting the first support bracket 26 to the driver's side A-pillar, bolting the second support bracket 28 to the passenger's side A-pillar, and bolting the main beam support mounting bracket 34 to the vehicle floor/frame.

The following is provided to generally describe an alternative method of assembly of the main beam support 32 and the associated components. Due to dimensional differences of components of the hanger beam assembly 20 and alignment issues when installing the hanger beam assembly 20 into the vehicle, difficulties may be encountered after attaching the first and second support brackets 26, 28 to the respective A-pillars. Specifically, the main beam support mounting bracket 34 may not be at the proper elevation to allow connection to the vehicle floor/frame. Alternatively, manufacturing requirements may dictate that the main beam support mounting bracket 34 be attached to the vehicle floor/frame before attachment to the main beam support 32.

Because of the oblong shaped first and second sockets 32 e, 32 f that will be discussed in more detail hereinafter, the dimensional/alignment problems mentioned above are easily addressed. In situations where the main beam support mounting bracket 34 has been attached to the hanger beam assembly 20 and it is discovered that the main beam support mounting bracket 34 is at an elevation that prevents attachment to the vehicle floor/frame, the main beam support mounting bracket 34 may be disconnected from the main beam support 32. Then, the main beam support mounting bracket 34, and hence the hanger beam assembly 20, may be adjusted in an up/down direction so as to alleviate the dimensional/alignment problems in the vertical direction between the hanger beam assembly 20 and the vehicle. In addition, when the main beam support mounting bracket 34 is already attached to the vehicle floor/frame, but not attached to the main beam support 32, the above described method is equally applicable. The hanger beam assembly 20 may be moved in the up/down direction to adjust for dimensional/alignment problems in the vertical direction between the hanger beam assembly 20 and the vehicle. The oblong shaped first and second sockets 32 e, 32 f are larger in diameter than the mounting posts 34 c, 34 d. Accordingly, the first and second sockets 32 e, 32 f may accommodate elevational differences between the hanger beam assembly 20 and the main beam support mounting bracket 34.

As mentioned hereinbefore, the first and second sockets 32 e, 32 f of the main beam support 32 are adapted to receive the corresponding mounting posts 34 c, 34 d that extend from the main beam support mounting bracket 34. The first and second sockets 32 e, 32 f of the main beam support 32 include the downwardly directed extensions 32 i, 32 j for receipt of integral keys 34 k, 34 l of the mounting posts 34 d, 34 e.

It is noted that the main beam support 32 is disposed so that the first and second sockets 32 e, 32 f on the lower end 32 b engage the main beam support mounting bracket 34 on a first or right side, while the mounting pad 32 c on the upper end 32 a engage the main beam hanger 30 on a second side or left side. By situating the main beam support 32 so that attachment occurs on the first and second sides, structural stability is increased.

The first and second sockets 32 e, 32 f are oblong shaped. Furthermore, the first and second sockets 32 e, 32 f include perimeter walls 32 k, 32 l that extend in a generally horizontal direction from the back wall 32 m of the main beam support 32. The oblong perimeter walls 32 k, 32 l receive the mounting posts 34 d, 34 e. It is noted that the downwardly directed extensions 32 i, 32 j created in the perimeter walls 32 k, 32 l have angled edges that aid in alignment and interaction with the integral keys 34 k, 34 l.

The mounting posts 34 d, 34 e can be inserted into the oblong perimeter walls 32 k, 32 l until a front face of the mounting posts 34 d, 34 e contacts the back wall 32 m of the first and second sockets 32 e, 32 f. The back wall 32 m is a generally vertical wall that laterally faces toward the first support bracket 26. The back wall 32 m includes the slotted opening 32 g that receives a threaded fastener to attach the main beam support 32 with the main beam support mounting bracket 34.

As is shown in FIG. 11, the mounting posts 34 d, 34 e are generally circular in shape and extend from the end wall 34 c in a generally horizontal direction. As is also shown in FIG. 11, the integral keys 34 k, 34 l extend downwardly in a height direction from the mounting posts 34 d, 34 e to a bottom wall 34 m of the main beam support mounting bracket 34 at a constant height. The integral keys 34 k, 34 l cooperate with the downwardly directed extensions 32 i, 32 j of the first and second sockets 32 e, 32 f during assembly as will be more fully described hereinafter.

From a side view as is shown in FIG. 11, as the integral keys 34 k, 34 l extend downward, the integral keys 34 k, 34 l preferably taper in thickness from a maximum thickness near the mounting posts 34 d, 34 e to a minimum thickness near the bottom wall 34 m of the main beam support mounting bracket 34. It should be noted that the integral keys 34 k, 34 l could maintain a uniform thickness between the mounting posts 34 d, 34 e and the bottom wall 34 m.

FIG. 12 illustrates that the integral keys 34 k, 34 l laterally extend from the end wall 34 e along a length of the mounting posts 34 d, 34 e. As is also shown in FIG. 12, the integral keys 34 k, 34 l extend in a constant height direction between the mounting posts 34 d, 34 e and the bottom wall 34 m.

FIG. 13 illustrates a main beam support assembly 50. Through the cooperation of the integral keys 34 k, 34 l with the downwardly directed extensions 32 i, 32 j, alignment of the main beam support 32 with the main beam support mounting bracket 34 is improved. The taper of the integral keys 34 k, 34 l further assists in the alignment of the main beam support 32 and the main beam support mounting bracket 34.

Furthermore, the integral keys 34 k, 34 l may interface with angled edges of the downwardly directed extensions 32 i, 32 j so as to better align the main beam support 32 with the main beam support mounting bracket 34, thereby simplifying installation of a fastener through the slotted opening 32 g and the associated hole in the main beam support mounting bracket 34. In general terms, the interaction between the integral keys 34 k, 34 l with the downwardly directed extensions 32 i, 32 j is somewhat similar to that of a key and a keyway arrangement as is known in the art. However, the thickness of the integral keys 34 k, 34 l is preferably tapered. This provides a convenient means to align the main beam support 32 with the main beam support mounting bracket 34, while still allowing for adjustment of the main beam support 32 in the vertical direction. Specifically, because of the interaction between the integral keys 34 k, 34 l and the downwardly directed extensions 32 i, 32 j and the interaction between the mounting posts 34 d, 34 e and the first and second sockets 32 e, 32 f, differences in vertical space between the main beam support 32 and the main beam support mounting bracket 34 can be accommodated.

In addition, since the integral keys 34 k, 34 l may rest on the angled edges of the downwardly directed extensions 32 i, 32 j any force that would be transmitted to the mounting posts 34 d, 34 e is also distributed through the integral keys 34 k, 34 l to the angled edges of the downwardly directed extensions 32 i, 32 j and into the perimeter walls 32 k, 32 l.

It is considered apparent that the external diameter of the mounting posts 34 d, 34 e is less than the internal diameter of the perimeter walls 32 k, 32 l of the first and second sockets 32 e, 32 f. In addition, it is noted that the mounting posts 34 d, 34 e are of a generally undersized circular cross-section, while the perimeter walls 32 k, 32 l of the first and second sockets 32 e, 32 f are of a generally oblong oversized shape. Because of this, additional freedom in the horizontal and vertical directions is allowed when aligning the main beam support 32 and the main beam support mounting bracket 34. As mentioned hereinbefore, the slotted openings 32 g also assist in allowing additional freedom of movement during alignment of the components.

Furthermore, it is also considered apparent that at least a portion of the thickness of the integral keys 34 k, 34 l is less than a width of the downwardly directed extensions 32 i, 32 j. This ensures that that the main beam support 32 can be aligned with the main beam support mounting bracket 34.

The hanger beam assembly 20 of the present invention provides a relatively light-weight structure to which the steering column assembly, dashboard and associated components may be secured. Further, the components of the hanger beam assembly 20 provide a desired natural frequency at the steering wheel. More specifically, it has been found that the natural frequency at the steering wheel is affected by the hanger beam assembly 20 materials as well as the spacing between the steering column and the driver beam 22 to which the steering column assembly, via the steering column support brackets 40, is secured. By forming the hanger beam assembly 20 from aluminum, it is possible to provide a desired natural frequency (e.g., 42 Hz) at the steering column assembly 37 while retaining a relatively short spacing. Notably, the structural integration and cooperation between the driver beam 22, first support bracket 26, steering column support brackets 40, main beam hanger 30, main beam support 32, and main beam support mounting bracket 34 is considered to directly affect the frequency response at the steering column assembly 37. Thus, by securely affixing these components to one another, and by providing a stiff connection to the vehicle floor via the main beam support mounting bracket 34, the desired natural frequency at the steering column assembly 37 results. This result is an improvement over known steel hanger beam assemblies in which, at the identical desired spacing, inherently provides a natural frequency that is reduced (i.e., about 33 Hz) and therefore has an undesirably frequency response.

The main beam support 32 of the present invention greatly simplifies assembly of the hanger beam assembly 20. Specifically, assembly of the main beam support 32 with the main beam hanger 30 and the main beam support mounting bracket 34 is improved. As described hereinbefore, at the lower end 32 b of the main beam support 32, the first socket 32 e is disposed relatively vertically above and rearward of the second socket 32 f. Furthermore, the mounting posts 34 d, 34 e of the main beam support mounting bracket 34 are disposed so as to be aligned with the first and second sockets 32 e, 32 f. As the first and second sockets 32 e, 32 f are oblong and oversized, they easily receive the undersized circular mounting posts 34 d, 34 e. This allows for increased accommodation of differences in vertical space between the main beam support 32 and the main beam hanger 20.

At the upper end 32 a of the main beam support 32, the pair of threaded holes 32 d allow for the receipt of the fasteners for securement of the main beam hanger mounting arms 30 d. This multi-point mechanical attachment and multi-plane engagement at the upper and lower ends 32 a, 32 b results in a secure connection between the main beam support 32 and main beam support mounting bracket 34.

Furthermore, because of the first and second sockets 32 e, 32 f, there is an allowance for tolerances or differences in components of the hanger beam assembly 20. For example, the sockets 32 e, 32 f only limit possible motion of the main beam support 32 in the forward/rearward and up/down directions after being aligned with the main beam support mounting bracket 34. It is not until fasteners are passed through the slotted opening 32 g that lateral motion of the main beam support 32, relative to the main beam support mounting bracket 34, is prevented. Accordingly, dimensional flaws in the hanger beam assembly 20 can be accommodated, thereby simplifying installation and assembly of the hanger beam assembly 20 in the vehicle. 

1. A main beam support for use in a vehicle, comprising: an upper end with a mounting pad and a threaded hole for attachment to a main beam hanger; and a lower end with a first socket that is disposed relatively vertically above and rearward of a second socket, wherein the first socket and the second socket are laterally open bores with oblong shaped perimeter walls that extend outward from the main beam support, wherein the perimeter walls of the first socket and the second socket each include a downwardly directed extension with angled edges for receiving an integral key, and wherein the first socket and the second socket each include a laterally facing back wall that is closed except for a slotted opening.
 2. The main beam support according to claim 1, wherein a pair of mounts with threaded openings are disposed between the upper end and the lower end.
 3. The main beam support according to claim 1, wherein each said slotted opening receives a threaded fastener.
 4. A main beam support assembly for use in a vehicle, comprising: a main beam hanger that extends between a vehicle A-pillar and a main beam; a main beam support mounting bracket with a bottom wall and an end wall, wherein the bottom wall is affixed to a floor of the vehicle, and mounting posts horizontally extend from the end wall, and wherein integral keys extend vertically from the mounting posts toward the bottom wall; and a main beam support with an upper end and a lower end, wherein the upper end is mechanically secured to the main beam hanger with fasteners that extend through a threaded hole of a mounting pad of the main beam support, and the lower end is mechanically secured to the end wall of the main beam support mount bracket, wherein first and second sockets include oblong shaped perimeter walls with downwardly directed extensions, and wherein the perimeter walls horizontally extend from the main beam support and cooperate with the mounting posts and integral keys of the main beam support mounting bracket to restrict movement of the main beam support.
 5. The main beam support assembly according to claim 4, wherein the first socket and the second socket each include a laterally facing bottom surface that is closed except for a slotted opening.
 6. The main beam support assembly according to claim 4, wherein the downwardly directed extensions support a downward force passed through the integral keys.
 7. The main beam support assembly according to claim 4, where said first socket is disposed relatively vertically above the second socket.
 8. The main beam support assembly according to claim 4, where said first socket is disposed relatively rearward of the second socket.
 9. The main beam support assembly according to claim 4, wherein an inner diameter of the first socket and the second socket is larger than an outer diameter of the mounting posts.
 10. The main beam support assembly according to claim 4, wherein movement of the main beam support in up/down directions is prevented after the first socket and the second socket engage the mounting posts.
 11. The main beam support assembly according to claim 4, wherein movement of the main beam support in forward/rearward directions is prevented after the first socket and the second socket engage the mounting posts.
 12. The main beam support assembly according to claim 4, wherein a pair of mounts with threaded openings are disposed between the upper end and the lower end.
 13. The main beam support assembly according to claim 5, wherein each said slotted opening receives a threaded fastener.
 14. A method of assembling of a hanger beam assembly, comprising the steps: attaching a main beam support mounting bracket onto a vehicle floor; attaching a driver beam and a main beam to respective vehicle A-pillars; aligning first and second sockets of a main beam support with mounting posts of the main beam support mounting bracket; aligning integral keys of the main beam support mounting bracket with downwardly directed extensions of the main beam support; inserting the mounting posts into the first and second sockets; and fastening the main beam support to the main beam support mounting bracket. 